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Pelleting: The link between practice and engineering

A feedmill needs to produce pellets in a hygienic way with the least costs and the highest efficiency. This cannot be realised without the close relationship between the operators in the field and the engineers at the drawing table.

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FEATURE FEATURE CPM has overcome this problem by sion. developing the Hot Start Mixer, which func- “Do you real- tions as a buffer in the start-up ise that a gear of the conditioning process. box has an over The paddles and screw in the 11 percent higher first section of the hygieniser efficiency than a at start-up turn in reversed two stage V-belt direction until the mash has reached the drive?” Lange says. required temperature and then the direction “Do you real- is changed and the mash can flow through ise the savings? For the hygieniser. There is no more need for a 250kW with an Pelleting: and engineering The link between practice The Quick Change clamps enable the operators to change which die within half all hour a bypass and the full batch of the feed can operating time of CPM is again setting be used without chance of recontamination. 6,000 hours per the standard for the year and an ener- future with the Specialist in pelleting gy price of eight recently award Around 50 percent of all pellet mills used eurocents per winning developed This conditioning of the mash has several in the world are made by CPM. kWh this would roll speed A feedmill needs to produce pellets in a of these machines consider their business advantages. Proper conditioning ensures a So the company indeed can call itself mean a energy measurement system hygienic way with the least costs and closer related to science. But this science can better pellet quality (hardness, durability) a specialist in pelleting. Pelleting is not just cost of €120,000. the highest efficiency. This cannot learn from the pelleting artists by developing resulting in better conversion rates with the use of a machine that turns ground and At 11 percent be realised without the close relationship and implementing demands and views from the animals. Conditioning improves pel- mixed ingredients into pellets, it is a process higher efficiency between the operators in the field and practice. let mill capacity, reduces electrical power and begins after the grinding process with this would mean a the engineers at the drawing table. The engineers at CPM Europe are the use and reduces wear of dies and rollers. conditioning, followed by the actual pellet- saving of €13,200 last ones to deny that practice is closely Furthermore with conditioning more dif- ing and then cooling of the hot pellets and in the advantage Through this cooperation equipment intertwined with their work on the computer ficult (cheaper) ingredients can be used. where applicable the addition of fats. of a gear box manufacturer CPM Europe in Amsterdam, controlled drawing programs. Conditioning is a combination of moisture Pelleting is also about energy consump- drive.” “Our close rela- addition, (steam and/or water), mechanical tion. The way the die and the die rolls are tionship to practice treatment (kneading and shearing) and ther- positioned largely determine how much Quick die“Through higher temperatures the and our ability to mal treatment (time/temperature). energy can be added to the product. change translate practical Especially the last feature has become There is a close relationship between Every pellet improvements into essential in feed manufacturing. energy consumption and pellet quality. The plant operatorfeed is hygienised and bugs are factual equipment has Through higher temperatures the feed more energy is put into the pellet the better knows the burden delivered us almost is hygienised and bugs are already killed in its quality will be. At the pellet mill this is of changing a die.already killed in the conditioner. always a competitive the conditioner. CPM was at the forefront limited to max. 20kWh/tonne. Not only is it advantage, which is of this development with the introduction The consumption of energy is also a heavy and timeCPM was at the forefront of this especially valuable in of the hygieniser or super conditioner. depending on the roller distance to the die. consuming job, an industry, which is This piece of equipment has shown to be An increase in roller distance will result it also adds con-development with the introduction of not specifically known an extremely efficient conditioner before in higher energy consumption. To be able siderably to the for its innovative pelleting and it is much cheaper than to manage this process CPM developed down-time of thethe hygieniser or super conditioner” power,” says Peter an expander, which is also often used. the Lineator, which enables the operator to plant. The CPM Lange, sales manager Table 1 shows the differences between an adjust the roller distances while pelleting and engineering group at CPM Europe. expander and the hygieniser. thus gives him the opportunity to influence in Amsterdam pellet quality on the spot. developed a quick the Netherlands, has been able to launch Conditioning with Hygeniser Hot start mixer Energy efficiency is also depending on the die change system many ‘firsts’, which have later been adopted CPM is active in the grinding and pel- One small thing was still a problem: method of power transmission in the pellet for its 32" and 36" and copied to industry standards. leting section of the feed manufacturing when starting the conditioning process mill. For this reason CPM pellet mills operate pellet mills. Plant operators working in the feed indus- process. the first approximate 100kg do not reach with a gear box instead of double V-belt drive. The object try often consider the handling of their pel- Before pelleting the feed mash needs to the required temperature and have to be According to Lange, gearbox transmis- was to have the leting equipment to be an art. Manufacturers be treated before it enters the pellet mill. bypassed or discarded before pelleting. sions have a high efficient power transmis- pellet mill up and 30 | may - June 2011 Grain &feed millinG technoloGy Grain &feed millinG technoloGy may - June 2011 | 31

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FEATURE Despite the economic crisis Lange is quite satisfied with the order list of pel- let mills and other related equipment. A walk through their workshop close to the old Amsterdam docks confirm this. Loads of equipment are ready for shipping to customers all over Europe. Remarkable are the heavy 355kW motors on the pel- let mills. Hi there, I’m the Global Miller! “It is a development from the wood pelleting You can catch my daily blogs at http://gfmt.blogspot.com industry. The motors are available and we adjusted our gearbox to be able to With the lineator the distance between the roll and the die can automatically be adjusted. A new feature is roll speed measurement, which can protect the die from choking mount these heavies on Covering all aspects of the grain feed our mills,” Lange says. Also present in the and milling technology, with industryrunning with a new die only 30 minutes after working the roll speed measurement inten- workshop is a miniature feed mill or labora-the end of the previous batch. This means sively while operating the remote roller tory as it is being called at CPM. news stories, company press releases,that for the actual (hot) die change only setting Lineator. The new integrated roll “This enables us to test the most exotic book reviews, company profiles and20 minutes are being reserved. To meet speed measurement device is expected to raw materials from all kinds of industries tothis objective CPM installs a pneumatic the work with very little maintenance and high see if they are pelletable. We are always much more. hoist, automatic knives posi- accuracy. working on innovations. This way we can tioning, automatic roller adjust It was observed that at clean die and roll- stay one step ahead of competition and sup- type Lineator, 18 segments die ers, the roll speed measurement allows an ply good quality machines for a reasonable clamp type bear claw and pre- automatic ‘zero positioning’ of the Lineator. price,” he adds. A new edition to Perendale assembled die with stiffening Until now this ‘zero positioning’ proves Publishers Limited is our bookstore,ring and rotary cone. to be a rather subjective interpretation of California Pellet Mill group With this system two people can remove various operators. Different operators can The history of CPM dates back to which can be found ata die in less than four minutes and the same ‘pre-load’ the rollers differently against the 1883 in Californias Napa Valley when thepeople can fit a new die in less than five die to set the zero-position. With the roll California Pellet Mill Company manufac-minutes. The quick die change clamp can also speed measurement the zero-position is set tured presses, Crushers and stemmers forbe mounted on existing machines that have at the moment both rollers are rotating at winemakers. In 1931, the company revolu- www.perendale.com/browsebeen supplied by CPM in the last 10 years. nominal speed. tionised the feed processing industry with In practice influencing the pellet quality the introduction of the first commercially is reached by using a thicker successful pellet mill. It features books that have been die or BOA-compactor or expander. A few years later, in 1938, the Roskamp story began when John Roskamp formed reviewed in the Global Miller that are “With the roll speed meas- the Roskamp Huller Company. In the l980s, relevant to the agriculture industry as urement these become obso- Roskamp Champion was born with the pur- lete,” Lange says. chase of Roskamp Roller Mill Company and well as travel section, and a section “The Lineator can now be Champion Hammer Mills. used to put more energy into In 2002, CPM purchased Beta Raven containing earlier copies of the the pellet. The speed of the of St Charles, Missouri, USA, supplier of rollers is measured and if they computerised process controls and ingre- International Milling Directory right The hot start mixer accumulates feed until rotate too slowly a signal fol- dient scaling systems. In 2006, Century up-to-date. lows. The operator then can Extrusion, from Century Inc of Traverse City, the required temperature is reached and then take action to avoid choking of Michigan, was acquired. The latest acquisi- evacuates the feed and increases throughput the die.” tion was Crown Iron Works, a specialist inRoll speed measurement Hendrix installed the roll oilseed processing. World headquarters and speed measurement and operates the by- Roskamp Champion production facilities are Blogs are maintained daily from Monday to Friday and we are happy to publish The latest innovation in combination with pass “quick dump feed chute” if the roller located in Waterloo, Iowa. In Asia, CPM isthe Lineator is die roll speed measurement, speed passes the minimum value of 320rpm. present in Singapore and has production any of your companies’ press releases about future events. You can also followwhich was put into service in July of this year. The experience is that after a roller runs facilities in Wuxi, China. Other plants are us on Twitter and Facebook; we look forward to hearing from you and wish youHendrix-UTD in Lochem (NL) has already under speed condition that the chokes and located in Crawfordsville, Indiana; Merrimack,been working with roll speed measurement the main engine overloads. New Hampshire, USA, and Amsterdam, The every success in the futurefor approximately 10 years at the available According to Lange the Lineator with roll Netherlands. The Global MillerCPM 7730-7 and 7932-9 pellet mill series. speed measurement reaches its highest poten- CPM is owned by Gilbert Global Equity The maintenance of this self-constructed tial when a relatively thin die is used. Pellet Partners. This strategic and financial partner-system is time consuming. quality and throughput can be influenced up to ship has enabled CPM to grow organically However, the production employees are 30 percent and less die changes are needed. and by acquisition.32 | may - June 2011 Grain &feed millinG technoloGy

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This digital Re-print is part of the May | June 2011 edition of Grain & Feed Milling Technology magazine. LINKSContent from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com. May 2011 • See the full issue • Choosing the right Hazard Monitoring System • Visit the GFMT website In this issue: • Contact the GFMT Team • Conditioning • Synthesis of as part of the animal feed pelleting process formulation techniques: Linear and Non-Linear model • Pelleting: • Pellet • Subscribe to GFMT The link between production practice and engineering to save energy, improve feed efficiency and safety A subscription magazine for the global flour & feed milling industries - first published in 1891To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact our Circulation and Subscriptions Manager on the link adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints www.gfmt.co.uk PREVIOUS PAGE